Operating Instructions
Contents
1. 4 Single motors on two same diameter rings with two toothed belts 4 Twin motor on one diameter ring with two toothed belts 4 5 Twin motors on two different diameter rings with four toothed belts nenne nenne 5 Single motor and twin motors on three different diameter rings with five toothed belts 5 Prebar ng for installation Re 6 Setting the hollow shaft encoder Tati rv tuae dn e ed eei bud ln ei 6 Setting the toothed Delt lengtTis osito toa ein es label en 6 Removing the toothed belts the tensioning devices and the quality adjustment pulleys 6 ASSEMDIY Rm 7 Fitting the hollow Shalt Encoder nee Reale T mper CONU OLUNM NR NEN a rr 8 Fitting the Capacitor battenes Optional nidos A 8 Connecting up the step down transformer optional sise 8 FLUNG NE MRAZ MOOS ee een 9 TAS ENSIONING cc E 10 Ng THC TOOTS Dells ea a en eu ee nee 10 Fitting the ST a consola iio 10 Terminal CONNECTION AAN A a 11 Sono Ringe aac E deere tee 11 COHNECLONS2. 11 DST ALLO a 12 GTS console GIS DIAY MEM ts 12 ACCESS evel MENU dead cm der editeur 12 COMMGUPAH OM MON telnet anne ITEM 13 Setting the hollow shaft encoder for the set yarn feed rate 15 Fabric press Om reciclado 16 Device INTORMATON IN TAE 16 and status message Mena nie anna a N 17 CONS OLS MONS de et m V nem 17 Y 18 HEOUDIESNOOHNG riesen Er rp 18 DIMENSIONS cerraron c r 19 MRAZ IMOT tes eos 19 CONTON tace ee se ee 20 SPS CONS A 21 FIOMOW SAAN encoder ee len 21 D claration or Manufacturer sii 22 Safety MEMMINGER TO Permitted uses The MRA 2 system is designed solely for feeding yarn to textile machines All other uses are not permitted The manu facturer will not accept any liability for damages resulting from non permitted uses The user is liable for damages resulting from non permitted uses Safety precautions No special training is required to operate an MRA 2 system The operator is responsible for ensuring that all instructions regarding the electrical installation fitting operation and maintenance of the MRA 2 are implemented The MRA 2 must only be installed and serviced by qualified electricians working in accordance with cur
3. gt Yarn feed rate reduction factor 1 To modify the reduction factor enter the password 2810 revolution number Number of machine revolutions for which fabric press off rectification is valid 2 MEMMINGER IRO gt Number of machine revolutions remaining until fabric press off rectification is automatically finished 3 gt Fabric press off rectification mode is active 4 INFORMATION At the end of the fabric press off rectification cycle the machine will stop The knitting proc ess can continue revolution number 2 2 Device information menu This provides information about the devices installed and their software Sw and hardware Hw versions MEMMINGER IRO e Device Status Menu x Control Unit Operation Fault and status message menu When a MRA2 system fault occurs this is indicated immediately on the GT 3 console display Console menu gt Software version of GT3 console 1 gt Modify the unit of measurement 2 metres or inches Es Change the user language EEE Setup gt Set the display contrast 3 4H Display adjustment AA Technical data Line voltage 3 x 400 V AC 10 Line frequency 45 66 Hz Power 250 VA per MRA 2 motor Max number of driven feeders 60 MPF units per belt per MRA 2 motor 24 MER units per belt per MRA 2 motor Max belt speed 360 m min with 30 tooth drive pulley 500 m min with 40 too
4. Assembly MEMMINGER TIO Fitting the control unit Fit the control unit to the drive bar or column or to the machine foot see the section Device Components Connect the MRA 2 motors to the control unit using the Power supply motor cables 1 8 or 3 0 metre lengths any CAUTION ZN mo MRA 2 must only be installed and serviced by qualified electricians working in accordance with current electrical engineering practices and regulations Before you connect or disconnect a motor cable you must power down the knitting machine Wait two minutes before unplugging the motor cable yellow green black black black In the event of a mains power failure knitting machines continue to run on for some time In the event of a power failure a MRA 2 system without capacitor batteries will stop the yarn feed immediately and this could cause yarn breakage Fitting the capacitor batteries optional On an MRA 2 system with capacitor batteries the capacitor batteries will continue to power the MRA 2 system until the knitting machine has come to a complete standstill The number of capacitor batteries required depends on a variety of factors and can only be decided on site The factors influencing the number of batteries required includes machine speeds rotating mass open wide knit ting machines general condition of the knitting machine number of MRA 2 motors fitted motor power required yarn sensitivity gt Fit the capacitor batteri
5. Access Level Menu X MEMMINGER IRO 1 Operation gt Access level 1 E or 2 I will be granted gt leave the menu use the x button INFORMATION If the touch pad is not touched for two minutes the access level rights will be automatically withdrawn Configuration menu gt Number of teeth the toothed belt pulley of the MRA 2 motor 1 the default value is 30 gt Number of hollow shaft encoder revolutions per machine revolution i e the ratio between the machine cylinder and the hollow shaft encoder 2 INFORMATION 1 Enter the ratio on the system before you install theunit see the section Setting the hollow shaft encoder ratio gt Number of pulses per hollow shaft encoder revolution 3 Take the value from the hollow shaft encoder the default value is 2000 gt Enter the values using the touchpad 4 CAUTION N In the interests of your own safety please enter all the necessary data on the GT3 console Operation MPF MER E MER C MCF MER B MEMMINGER IRO gt Feeder type selection list 1 gt Yarn feed rate per feeder revolution 2 Number of teeth on feeder toothed pulley 3 If a feeder is not on the feeder list 1 you must enter the yarn feed rate per feeder revolution 2 and the number of teeth on the toothed pul
6. 2 system off and then on again Device Status menu 18 u CAT TL TEIL TEILTE ID Dimensions Dimensions Control unit MEMMINGER IRO 20 Dimensions MEMMINGER IRO GT3 console Hollow shaft encoder Declaration of Manufacturer MEMMINGER IRO Declaration of Manufacturer in accordance with the Machinery Directive 98 37 EC Annex II B for machinery components in accordance with the Low Voltage Directive 73 23 EC in accordance with the Electromagnetic Compatibility Directive 89 336 EC The manufacturer MEMMINGER IRO GmbH Jakob Mutz Stra e 7 D 72280 Dornstetten Germany hereby certifies that the following product MRA 2 conforms to the requirements of the above named directives The following harmonised standards were used EN ISO 11111 Textile machinery Safety requirements EN ISO 12100 Safety of machinery EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61000 4 2 Electromagnetic compatibility EMC Part 4 2 Testing and measurement techniques Electrostatic discharge immunity test EN 61000 4 3 Electromagnetic compatibility EMC Part 4 3 Testing and measurement techniques Radiated radio frequency electromagnetic field immunity test EN 61000 4 4 Electromagnetic compatibility EMC Part 4 4 Testing and measurement techniques Electrical fast transient burst immunity test EN 61000 4 5 Electromagnetic co
7. for any reprogramming Components MRA 2 motor The MRA 2 motors receive control signals from the control unit and drive the toothed belts at the speed for the set yarn feed rate In order to handle speed changes manual operation and starting and stopping the motor incorporates advanced control technology The MRA 2 motor incorporates a frequency converter which Description converts line current into three phase alternating current with variable frequency No additional electrical cabinet is required because the converter is already incorporated in the motor GT3 console The GT3 console is used to enter all the parameters needed to install and operate the system Control unit The control unit is powered from the mains power supply at 3 x 400 V AC It can power up to six MRA 2 motors It stores operating parameters and distributes information from the GT3 console and the hollow shaft encoder The GT3 console is used to enter the yarn feed rate and displays the information about machine movements received from the hollow shaft encoder This information is processed by the control unit and then transmitted to the MRA 2 motors Hollow shaft encoder The hollow shaft encoder is installed on the drive shaft and is connected via a gear box to the machine cylinder The hollow shaft encoder detects cylinder movements translates these into pulses and transmits the pulses to the control unit Capacitor batterie
8. Operating Instructions MEMMINGER IRO GMBH D 72277 DORNSTETTEN english 027 920 000 01 27 05 09 Introduction Contents MEMMINGER IRO Introduction Congratulations and thank you for choosing a quality product from MEMMINGER IRO To ensure that you get top performance from this product you should be fully familiar with all its features and functions This is why we ask you to read this instruction manual carefully before starting to use the product The manual contains precautions operating instructions and other useful information about how to make the best use of this product Keep this manual where it will be readily available for reference Table of contents INtTOAUCLHON ss ne te cv ueuteodee 1 COMENS kiss Ses Serene o eE TO 1 rjr PEE 2 P 2 D eV AV Dresd eo A E 2 VIEL IV M M mI EM MEE MAE MEE 2 DISDOS al PME EE EE 2 Symbols USC AA ea ee 2 LSS CHD CLO C Eee 3 COImpohelliss seda one esi eiae elle Es 3 o se ee ee ee ee re Hn Ae 3 COINMDONONIS eI rct ETT 3 Installation ODHONS HH t 4 Single motor on one diameter ring with one toothed belt 4 Single motors on two different diameter rings with two toothed belts
9. es to the machine foot and connect them to the control unit see the control unit terminal connection diagram Power supply from knitting machine Connecting up the step down trans 3 x 440 585 V 50 60 Hz former optional 985 V 985 V 985 V The MRA 2 system operates a rated voltage of 400 V AC 930 V 2t N At input voltages greater than 400 V AC and up to 585 485 V 485 V 485 V 440 V A40 V A40 V V AC you must fit a step down transformer between the knitting machine and the control unit gt Fitthe step down transformer in the electrical cabinet or on the machine foot l Power supply for the control unit 3 x 400 V 50 60 Hz Assembly MEMMINGER IRO Fitting the MRA 2 motors m TT Attach the MRA 2 motors 7 to the motor flange 3 with the cheese head screws 5 Adjust the toothed pulley 2 with the cone clamping element 1 to the same height as the tension roller 4 on the drive shaft 6 of the MRA 2 motor 7 Fix the MRA 2 motors 7 with the motor flange 3 to the feed ring 8 of the machine ES 8 I INFORMATION ES 1 In orderto prevent vibrations onthe feeder ring i SNE the MRA 2 motors should be mounted close to a ring support bracket wherever possible OO INFORMATION To loosen the cone clamp unscrew the screws by a few turns Unscrew and remove two of the screws and then screw them into the two bores by the same amount This will force the outer cone shell out o
10. f the inner shell and thus release the connection Assembly MEMMINGER TIO Fitting the tensioning device gt Fit the tensioning device to the feeder ring CAUTION The MRA 2 should only be used with an unsprung tensioning device Fitting the toothed belts gt The motor flange tension roller 1 the MRA 2 motor toothed pulley 2 and the feeder toothed pulley must all be adjusted to the same height This is ensure that the toothed belts do not run up against the flanks of the tension rollers belts will be damaged if they run up against the flanks gt Do not kink or twist the toothed belts Fitting the GT 3 console gt Fitthe GT 3 console to the motor flange of the MRA 2 motor gt The GT 3 console can also be fitted to a bar MEMMINGER IRO Control unit MRA 2 Motor MRA 2 Motor Motor cable Terminal connection diagram 24V CANHCANLGND 24V B GND C NO NC SOSSE ST 3 O Mit a 250 kbit s 500 kbit s Standard GT3 console Hollow shaft owitching off encoder Power supply 3 x 400 V AC MRA 2 Motor MRA 2 Motor MRA 2 Motor or capacitor batteries CAUTION CAUTION Before you connect or disconnect a motor Atinput voltages greater than 400 V AC and cable you must power down the knitting machine Wait two minutes before unplugging the motor cable and the control uni
11. ley 3 using the touchpad You cannot modify the default settings forthe MPF MER B MER C and MCF feeders Set the direction of rotation of the toothed belts during configuration INFORMATION The direction of rotation should be the same as that of the knitting machine toothed belts Operation MEMMINGER IRO Product specific default control parameter settings for service personnel speed D1 Pos PA Speed 02 speed Controller shift pos 1 7 Speed PZ Motor ramp 260 speed l1 Friction compens 5 Speed 2 Friction slope 2 Setting the hollow shaft encoder for MRA the set yarn feed rate gt Enter the yarn feed rate per machine revolution set before assembly see the section Setting the hollow shaft encoder ratio gt Start the knitting machine gt Measure the actual yarn feed rate per machine revolution gt Ifthe actual yarn feed rate does not match the origi nal yarn feed rate you must adjust the hollow shaft encoder ratio gt Start the knitting machine and measure the actual yarn feed rate per machine revolution again gt Repeat this procedure until the actual yarn feed rate per machine revolution matches the yarn feed rate measured before installation on the knitting machine Operation Fabric press off rectification X Press Off recovery mode __ un f Start fabric press off rectification 1 reduction factor F Stop fabric press off rectification 80
12. mpatibility EMC Part 4 5 Testing and measurement techniques Surge immunity test EN 61000 6 4 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments The machine components are complete with original operating manuals and technical documentation This machine may only be operated when it is certified that its components conform to the requirements of the machinery directives 5 Dornstetten 11 12 2006 M Kleindorp Company Management 22 MEMMINGER IRO GmbH Tel 0 7443 281 0 Postfach 1240 Fax 0 7443 281 101 D 72277 DORNSTETTEN E Mail info memminger iro de Jakob Mutz Stra e 7 Internet www memminger iro de D 72280 DORNSTETTEN 2006 MEMMINGER IRO GmbH D 72277 DORNSTETTEN Nachdruck auch auszugsweise nur mit schriftlicher Genehmigung der MEMMINGER IRO GmbH nderungen vorbehalten Reprint even in extracts shall require the written approval of MEMMINGER IRO GmbH Subject to modifications
13. n this manual Disposal You should dispose of MRA 2 components in compliance with the regulations for the disposal of electrical and elec tronic components Symbols used in this manual CAUTION N This symbol marks important instructions where failure to follow the instructions can cause personal injury or damage to the equipment INFORMATION This symbol marks useful information which will help you to get the best from the equipment MEMMINGER IRO Unit components MRA 2 motors GT3 console Control unit Hollow shaft encoder Capacitor batteries Function The hollow shaft encoder detects and measures machine movements and rotation translates this measurement into a signal and then sends the signal to the control unit where it is used to control the MRA 2 motor The GT3 console is used to precision set the yarn feed rate for each individual belt The yarn feed rate for fabric press off rectification can be reduced by programming The MRA 2 motors can run in both directions This means that the feeder for S and Z yarns can be run with left handed or right handed direction of rotation In the event of a mains power failure capacitor batteries will continue to power the system until the machine has come to a complete standstill If a fault occurs during an operating cycle the machine will be powered down it will not be possible to restart the machine MRA 2 motors can be exchanged when required without the need
14. rent electrical engineering practices and regulations y The MRA 2 has electronic components which are sensitive to interference from electrostatic charges Before you open the equipment housing you should take precautions to prevent electrostatic charges You can AR discharge any electrostatic charges beforehand by touching an earthed object such as the machine or the earth contact of a socket The MRA 2 system is designed for operation with a 3 x 400 V AC power supply The power supply for the MRA 2 must be taken from the circular knitting machine The power supply to the MRA 2 must be switched on and off from the main switch of the circular knitting machine This means that the MRA 2 can only be powered up when the machine is powered up When the machine is turned with the hand lever the unit must be ready for operation Before you start any adjustments even small ones you must power down the knitting machine Power up the equip ment only after you have completed these adjustments In the interests of your own safety please enter all the necessary data on the GT3 console Before you start any adjustment of the unsprung tensioner device power down the circular knitting machine Only use original spare parts and accessories Warranty Failure to follow the instructions in this manual will void your warranty The manufacturer will not accept any liability for damages or operating faults resulting from failure to follow the instructions i
15. s In the event ofa mains power failure the batteries ensure that the system continues running until the machine has come to a complete standstill this prevents yarn breakage Installation options 2 ui Y 2 C ii iui gt de C gt O C pes juni c S O cC C O dui gt Twin motors on two different diameter rings with four toothed belts Single motor and twin motors on three different diameter rings with five toothed belts Preparing for installation Setting the hollow shaft encoder ratio Before you fit the MRA 2 system you must set the ratio between the one machine revolution and the revolutions of the knitting machine drive shaft un p EM pd NN Example gt Rotate the machine through one revolution and count the number of revolutions of the quality adjustment pulley gt last revolution of the quality adjustment pulley must coincide with the end of the single machine revolution and should be counted at this point e g 1 machine revolution 10 8 quality adjustment pulley revolutions gt Measure the yarn feed rate per machine revolution You will need to know the yarn feed rate in order to fine adjust the hollow shaft encoder ratio see the section Setting the hollow shaft encoder for the set
16. t Electrical connections up to 585 V AC you must fit a step down transformer optional between the knitting machine gt Connect up the MRA 2 system as shown on the terminal connection diagram CAUTION The MRA2 must only be installed and serviced by qualified electricians working in accordance with current electrical engineering practices and regulations 11 Operation MEMMINGER IRO Layout of GT3 console display Memminger IRO Device information about the control unit and the MRA 2 motors ES Configure MRA 2 system I Fabric press off rectification amp Access level menu Fault status message El Console X Exit menu Next page The fields with a yellow background can be set accord ingly INFORMATION Before you can make any changes You must enter a valid password Access level menu amp No access permitted E Access level 1 for knitting machine operators with password 2810 Users at this level can modify the yarn feed rate per machine revolution modify the reduction factor in the fabric press off rectification mode and modify the number of machine revolu tions Access level 2 for machine setters with password 72280 Users atthis level can configure the encoder the number of teeth on the MRA 2 motor toothed pulley the feeder direction of rotation and the unit of measurement metres or inches used gt Enter a valid password
17. th drive pulley 5 6 m min with 48 tooth drive pulley Ambient temperature operation and storage 0 to 50 C Weight GT3 console 1 1 kg Weight hollow shaft encoder 0 9 kg Weight control unit 2 3 kg Weight MRA 2 motor with motor flange 6 2 kg Troubleshooting Fault after installation Possible cause The MRA 2 motor does not run Does the motor shaft vibrate for approx two seconds No Change the MRA 2 motor or the control unit when you switch on Before you connect or disconnect a motor cable you must power down the knitting machine Wait two minutes before unplugging the motor cable Yes Set the parameters correctly The MRA 2 motor does not run Check if the MRA 2 motor has any torque Turn the No Change the MRA 2 motor or the control unit motor shaft by hand Before you connect or disconnect a motor cable CAUTION you must power down the knitting machine Wait two Exercise extreme caution minutes before unplugging the motor cable i Yes Set the parameters correctly The yarn feed rate is too high The motor speed is too high Fit a toothed pulley with 48 teeth to the MRA 2 motor Fault message during oper Possible cause ating cycle Fault message You have entered an invalid password Enter a valid password Insufficient Permission Level You have not entered a password Access rights are withdrawn automatically after two minutes of inactivity Fault message Internal electronic fault owitch the MRA
18. yarn feed rate Setting the toothed belt length MPF unit on the feeder ring Toothed belt length ring outer diameter 200 mm x 3 14 500 mm MER unit on the feeder ring Toothed belt length ring outer diameter 150 mm x 3 14 500 mm Continuous toothed belts are available in sizes from 2 to 16 metres in steps of 200 mm Measure the belt length required for example 7100 mm and then use the next belt length up 7200 mm in this example Removing the toothed belts the tensioning devices and the quality adjustment pulleys Before youfitthe MRA 2 you mustfirst remove the toothed belts the tensioning devices and the quality adjustment pulleys You can also remove any unnecessary drive shafts and housings Assembly MEMMINGER IRO Fitting the hollow shaft encoder gt Fix the adapter 2 and the torque bracket 5 to the hollow shaft encoder 4 Fit the encoder support 6 to the torque bracket 5 gt Slide the hollow shaft encoder 4 onto the drive shaft 8 gt Screw the screw 1 ofthe adapter 2 into the keyway on the drive shaft 8 gt Attach the encoder support 6 to the drive bar column 9 of the knitting machine CAUTION Only the rotor 3 of the hollow shaft encoder 4 should rotate with the drive shaft 8 The torque support 5 should not be bent or kinked Fit the hollow shaft encoder 4 to the drive shaft 8 and then the quality adjustment pulley 7
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